This page was something I came up with waaay-back-when .. in fact it was my first PHP program. I scrounged up the mathematics and scripted the code. I'm by not any means claiming that this calculation is in any way shape or form gospel . I'm just making a case that .. it's worth thinking about and discussing.
Generalized explanation on sizing exhaust
Reducing exhaust backpressure increases airflow velocity and performance. Reducing restrictions using headers,
larger size exhaust tubing, shorter length, and installing high-flow catalytic converters and mufflers decrease
backpressure.
For street use, large tubing removes energy from the exhaust by slowing exhaust gas velocity; essential in creating
a vacuum behind the closed exhaust valve and cooling the gases. Exhaust gasses may be 1500 degrees or more at the
port but only 150 degrees at the tailpipe exit. (Turbocharged, NOS engines do not follow this because of pressure
differentials).
Reducing backpressure increases exhaust scavenging from the combustion chamber reduces mixture contamination and
increase high-end horsepower at the cost of low-end torque by an equivalent to increasing valve overlap. Increasing
backpressure is equivalent to decreasing the amount of valve overlap.
Backpressure can be increased by increasing intake velocity since the exhaust stroke must evacuate more air.
Increasing intake velocity past the limits of the exhaust system degrades the improvements to the exhaust system.
The total cross-sectional area of tailpipes on an engine should not exceed the total cross-sectional area of
primary header pipes (including race engines). The ratios for normal street and highway driving, street performance
and street-strip cars are about 45%, 50% and 60%, respectively.
Tailpipe Caculations
Engine has how many cylinders?
Select O.D. (inches) of Primary Header Pipes
Select gauge of Primary Header Pipes
Single or Dual Exhuast?
Single
Dual
Type of Driving?
Normal street and highway driving
Street performance
Street-Strip